Boat and method of construction

ABSTRACT

The specification discloses a novel boat and method of assembly thereof, specifically a houseboat. An interior module including all framing and interior paneling, finish, trim and fixtures is completed in a workshop area. A fiberglass exterior module with attached deck is lowered over the interior module and the complete house and deck portion is then lowered into the hull to form the completed boat.

United States Patent French 1 Mar, 1, 1972 [54] BOAT AND METHOD OF 3,531,809 10/1970 Hegg ..9/6 CONSTRUCTION 3,363,597 1/1968 Zeien 114/65 [72] Inventor: Calvin G. French, Winter Garden, Fla. Primary Examiner Andrew H. Farm" [73] Assignee: Ashland Oil, Inc., Houston, Tex. Attorney-William D. Hall, Elliott l. lPollock, Fred C. Philpitt, George Vande Sande, Charles F. Steininger, Robert R. Priddy [22] and Walter H. Schneider [21] Appl. No.: 14,663

[57] ABSTRACT [52] U.S.Cl. ..ll4/65R Th specification discloses a novel boat and method of asembly thereof pecifically a houseboat An interior module [58] Fneldl of Search ..296/ 31 P; 52/79; 1 14/65, 77 A including a" framing and interior pal-Ming, finish, m and tures is completed in aworkshop area. A fiberglass exterior [56] References cued module with attached deck is lowered over the interior UNITED STATES PATENTS module and the complete house and deck portion iS then lowered into the hull to form the completed boat. 2,368,441 1/1945 Bedford ..114/65 631,541 8/1899 Hewitt ..52/79 X 10 Claims, 8 Drawing Figures ERECT INTERIoR INSTALL DROP DECK 8 HOUSE 20 PANELlNG a TRIM WlTH WIRING SHELL ovER INTERIOR INTEGRAL FRAMING 6 UNIT ADD FRONT ON JIG lN FACTORY PLUMBING SHELL MOLD DECK 8 HOUSE L/ SHELL AND FRONT SHELL L L L DECK 8 HOUSE INSTA LL EXTERIOR FITTINGS Patented March 14,,1972 3,648,639

- 7 shaeks sheet 3 6' //r/ l o a.

IINVENTOR CALVIN G. FRENCH Patented March 14, 1972 7 Sheets-$heet 4 ATTOR N EY Patented March 14, 1972 3,648,639

Patented March 14, 1972 I 3,648,639

7 Sheem-Sheet 6 FIG. 7

muvm'ron CALVIN G. FRENCH ATTORNEY Patented March 14,, 197 3,648,639

7 Sheets-Sheet 7 unvnzmon CALVIN G. FRENCH BOAT AND METHOD OF CONSTRUCTION BACKGROUND OF THE INVENTION This invention relates to a method for boat building, particularly to a method of prefabricating boat sections, and more particularly to a method of assembling the completed sections in a unique and novel manner to drastically reduce the number of manhours required to construct said boat.

Over the years there has been a steady progress towards more efficient assembly of boats and ships, beginning in the days of wooden ships in which the frame was laid down upon the ways and the plates of the ship inside and out were fastened to the frame to form the hull portion. Today in small boat construction, this process has been largely eliminated by the formation of the hull envelope formed by fiberglass from a suitable mold. Likewise, the upper portion of small boats is generally formed from a plurality of fiber glass moldings which are joined together within the hull to form the deck and upper portions of the boat. Once the completed shell is finished, the interior studs and stringers are mounted within the hull and upper deck portion. Electrical wiring and plumbing is then run through the studs and stringers to the service outlets, and the proper interior finish such as paneling or other suitable wall finish is installed over the wiring and plumbing upon the studs and stringers.

All of this is quite laborious and time consuming as the individual components must be cut and fitted within the confines of the ship hull and upper deck portion. Thus, in the normal process the interior portion of the boat is the last to be finished.

The present invention however utilizes the formation and the completion of the interior portion first as a complete module. The upper portions of the house and deck molding are then lowered over the completed interior module. The complete interior and upper portion of the boat is then lowered into the hull envelope to complete the boat. This enables the workmen to fabricate the interior of the boat in a workshop area within the shipyard using modern day assembly jigs and other techniques. The individual panels utilized in the formation of the interior may be mass produced with the studs and stringers attached so that it is only necessary to erect a small number of panels to form a completed interior. It is also possible in this matter to easily install the wiring, plumbing, and other service facilities by drilling from the outside of the interior with a minimum of inconvenience and bother. This reversal of the normal boat building practice results in savings of almost fifty percent (50 percent) of the labor involved in constructing a small boat.

BRIEF SUMMARY OF THE INVENTION It is an object of this invention to provide a novel method for assembling a boat.

It is another object of this invention to provide a unique and novel method of assembling the interior of a boat.

It is another object of this invention to disclose a boat which may be constructed of individual prefinished modules and assembled with a minimum amount of time and labor.

It is another object of this invention to disclose a method whereby the interior of a small boat may be fabricated by utilizing assembly line techniques before it is installed within the hull portion.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing the method of construction utilized in the prior art.

FIG. 2 is a block diagram illustrating the novel method of constructing a boat.

FIG. 3 is an isometric view of a partial assembly of the interior module.

FIG. 4 is an isometric view of a partially completed interior module illustrating the installation of service units and trim.

FIG. 5 is an isometric view of a completed interior module.

FIG. 6 is an isometric view of the house and deck shell, the front shell and the mode of assembly.

FIG. 7 is an isometric view of the completed house and deck shell, the hull envelope, and the method of assembly.

FIG. 8 is an isometric view of the completed boat as mounted on a trailer for use as a house trailer.

DETAILED DESCRIPTION OF THE INVENTION FIG. ll illustrates in block form the prior art method of assembling a houseboat. A houseboat is utilized for the purposes of the detailed description, although it is understood that the same method could be used in the construction of any small boat, be it cruiser or sailboat.

The first step of the conventional method of assembling a boat is the molding ll of a hull shell from a suitable mold in fiberglass. The second step which is sometimes done concurrently in a separate area is the molding 12 of the deck shell. The third step which is also done at the same time is the molding 13 of the various front, rear, side and roof panels that will make up the exterior house of a house boat, the cabin of a cabincruiser, or the doghouse of a sailboat. The next step in the conventional assembly of a small boat is the mating 14 of the hull and deck assemblies into one unit. The next step 15 is to fabricate the house on the deck shell and hull with the front rear and side panels and the roof panels. In conventional practice, two to three roof panels would be required to fabricate the roof design illustrated in FIG. 8.

The next step in the conventional or prior art method of assembly would be the fabrication 16 of the interior framing within the deck house and hull. After the framing has been finished, the plumbing and other wiring is installed l7, various other service components such as motors, bilge pumps, exhaust vents, etc. are installed within the interior framing. After the completion of this installation, the interior is fabricated 18 wherein the paneling or other interior finish is attached to the studs and stringers and other framing members to complete the interior of the boat.

The assembly of completed units such as stoves, wardrobes, tables, lounges and other items are installed either immediately before or immediately after this step. The last step in the completion of the boat is the installation 19 of the exterior fittings and the hardware necessary for the operation of the boat. Upon occasion this is done simultaneously with the fitting of the interior finish and service components.

As illustrated in FIG. 2, the assembly techniques illustrated by this invention begin with the erection 20 of an interior unit. This unit as will be explained later is formed of panels with integral framing and is assembled on a jig in the factory work area. This assembly may utilize mass production techniques, if desired, to completely assemble an interior module complete with all paneling and trim, without involving any modifications or changes in the hull or other exterior members that is necessary in conventional boatbuilding techniques. Simultaneously with the assembly of the interior module, the deck and house shell and front shell illustrated are molded 21 at a separate location. Simultaneously also, the hull envelope is molded 22.

After the completion of the interior module, the wiring and plumbing is installed 20a from outside the interior module thereby vastly reducing the number of man hours required to install the service wiring and plumbing connections. After this has been completed, the deck and house shell is lifted over the interior module and lowered down over the interior module to form a completed interior and exterior house portion. Due to the configuration of the particular houseboat illustrated, it has been found desirable to fabricate the front shell portion in a separate mold, and it is installed after the interior module has been inserted into the deck and house shell 23. After the completion of this house and deck shell with its completed inner module, the entire assembly is then inserted 24 into the hull envelope and secured thereto. The exterior fittings are then installed 25 upon the houseboat to complete the assembly.

The assembly of the interior module is further illustrated in FIGS. 3, 4 and 5, wherein in FIG. 3, the floor member 26 is assembled on jig 27. After the floor member has been completed, the front 61 and side 62 wall portions are erected and temporarily clamped as illustrated at 28 until they can be secured to each other, and to the floor member. It will be noted that these wall panels have their own studs 63 and stringers 64 which are preassembled using mass production techniques in another work area of the plant. The primary assembly in the boat assembly area being the erection of the wall portions upon the floor portion and then the installation of the service components and finally the ceiling panel. As may be seen at 29, the final finish wall paneling is installed first.

As illustrated in FIG. 4, three sides of the module have been erected, the carpet (not shown) installed and the various inner service modules are installed. These modules include the range and cooking module 30 which is adapted to receive a small cooking unit, range and sink, and thereby provide space for the preparation of food. The control console 31 is installed along with a table and lounge module 32. Once these larger console units are installed the fourth side of the module and the roof members are erected as illustrated in FIG. 5. As will be noted in FIG. the interior module is completed and the various items of service wiring 33, interior plumbing connections (not shown) and control wiring connections (not shown) have been installed and run through the studs 63 and stringers 64 from the exterior of the module.

Having the interior unit at a convenient work level unit in the shop area of the factory enables a great deal of time to be saved in the formation of the studs and the stringers necessary to secure the inner paneling. Time is also saved in the installation of wiring, plumbing and other service requirements found on a small boat. In the present method of construction, the carpenters and other interior workmen do not have to lie within the confines of a small hull or housemember, and do not have to custom fit the stringers and studs against the boat hull.

Once the interior module is completed as illustrated in FIG. 5, it is moved to the assembly area illustrated in FIG. 6. Here, in the present example a house and deck shell 34 has been fabricated of fiberglass from a suitable mold. This shell includes the upper and exterior walls 35 and the deck portion 36. Due to the design utilized in the representative example, it was found more convenient to mold a separate front portion 37 with its attached front and deck portion 38 as a single unit and later join it to the remainder of the house and deck shell. The interior module is then inserted into the house and deck shell by raising the exterior module over the interior module and lowering it to align the two together. Once the two are aligned properly, the various adjusting shims are inserted and the two are fastened securely together. Once the two have been properly joined, the front portion 37 is then joined to the remainder of the house and deck shell and is securely attached to the interior module 50.

After the exterior and interior modules have been joined together and completed, the entire assembly 39 is lowered into the hull envelope 40 which has been previously molded at a separate location. The two are then joined at the seam along the gunwale 41 although it is understood that any suitable deck and hull configuration could be used which is desired, with each specific configuration requiring a different joining point.

After the completed house and deck shell module has been joined to the hull envelope as illustrated in FIG. 8, the various other members of exterior trim such as running lights 42, windows 43, and guardrails 44 are attached thereto and the finish painting and striping is completed.

In the present invention, a houseboat has been selected as it may be coupled with a boat trailer 45 illustrated in FIG. 8 and used as a house trailer for convenient trailering from point to point. If the occupants of the house trailer then desire to go boating, it is only necessary to lower the houseboat into the water for a convenient home on the water. The houseboat has been selected because it is a favorite of todays retiring citizens, and the economies found in this method of construction are quite readily apparent and desirable. By utilizing the present method of construction, the number of man hours necessary to complete the assembly of the boat from start to finish is almost halved. By cutting the labor required in half, the cost of the boat can be lowered considerably, thus adding to its desirability as a mobile home either on the land or water.

While a houseboat has been used as a specific embodiment, it should be understood that our method is applicable to other types of boats and cruisers, including large motor cabin cruisers. The accomplishment of the details of construction are known to the persons in the art, and it will be understood that the above embodiment of the invention is illustrative only and that modifications thereof will occur to those skilled in the art. Therefore, the invention is not to be limited to the specific apparatus and method disclosed herein but is to be defined by the appended claims. I

lclaim:

l. A method of constructing a watercraft comprising the steps of:

a. assembling an interior module for a watercraft, said interior module defining finished interior'surfaces and integral structural members for supporting said interior surfaces;

b. inserting said interior module into an exterior envelope for a watercraft;

c. securing said interior module to said exterior module; and

d. inserting said combined interior and exterior modules into a hull envelope for said watercraft and securing it thereto.

2. A method of boat construction as claimed in claim 1 which further comprises completely finishing said interior module and installing service connections within said module before said module is inserted into said exterior envelope.

3. A method of boat construction as claimed in claim 1 which further comprises the forming of a deck shell as an integral part of said exterior envelope.

4. A method of boat construction as claimed in claim 1 which further comprises:

a. the forming of said exterior envelope in two parts, a deck and house shell and a front shell,

b. inserting said interior module into said deck and house shell, and then c. joining said front shell to said deck and house shell to completely enclose said interior module.

5. A method of construction a watercraft comprising the steps of:

a. assembling an interior module for a watercraft complete with framing, interior finish and trim, said framing providing structural support for said interior module;

b. inserting said interior module into an exterior envelope for said watercraft to completely enclose said interior module;

c. securing the exterior envelope to said framing of said interior module; and

d. lowering said enclosed interior module into a hull envelope for said watercraft and securing it thereto.

6. A method of boat construction as claimed in claim 5 wherein said interior module is inserted into said exterior envelope by lowering said exterior envelope over said interior module and securing it thereto.

7. A method of boat construction as claimed in claim 5 wherein said exterior envelope comprises a deck and house shell and a front shell, said front shell 'being fitted to said deck and house shell after the insertion of said interior module.

8. A method of boat construction as claimed in claim 5 wherein said exterior envelope has a deck portion.

9. A method of boat construction as claimed in claim 5 wherein said exterior envelope is the complete upper portion and deck of a house boat.

10. A method of boat construction as claimed in claim 5 wherein said exterior envelope and said hull envelope are formed of fiber-reinforced synthetic resin. 

1. A method of constructing a watercraft comprising the steps of: a. assembling an interior module for a watercraft, said interior module defining finished interior surfaces and integral structural members for supporting said interior surfaces; b. inserting said interior module into an exterior envelope for a watercraft; c. securing said interior module to said exterior module; and d. inserting said combined interior and exterior modules into a hull envelope for said watercraft and securing it thereto.
 2. A method of boat construction as claimed in claim 1 which further comprises completely finishing said interior module and installing service connections within said module before said module is inserted into said exterior envelope.
 3. A method of boat construction as claimed in claim 1 which further comprises the forming of a deck shell as an integral part of said exterior envelope.
 4. A method of boat construction as claimed in claim 1 which further comprises: a. the forming of said exterior envelope in two parts, a deck and house shell and a front shell, b. inserting said interior module into said deck and house shell, and then c. joining said front shell to said deck and house shell to completely enclose said interior module.
 5. A method of constructing a watercraft comprising the steps of: a. assembling an interior module for a watercraft complete with framing, interior finish and trim, said framing providing structural support for said iNterior module; b. inserting said interior module into an exterior envelope for said watercraft to completely enclose said interior module; c. securing the exterior envelope to said framing of said interior module; and d. lowering said enclosed interior module into a hull envelope for said watercraft and securing it thereto.
 6. A method of boat construction as claimed in claim 5 wherein said interior module is inserted into said exterior envelope by lowering said exterior envelope over said interior module and securing it thereto.
 7. A method of boat construction as claimed in claim 5 wherein said exterior envelope comprises a deck and house shell and a front shell, said front shell being fitted to said deck and house shell after the insertion of said interior module.
 8. A method of boat construction as claimed in claim 5 wherein said exterior envelope has a deck portion.
 9. A method of boat construction as claimed in claim 5 wherein said exterior envelope is the complete upper portion and deck of a house boat.
 10. A method of boat construction as claimed in claim 5 wherein said exterior envelope and said hull envelope are formed of fiber-reinforced synthetic resin. 